Accelerated Test Program for the battery used in the M234 Self Destruct Fuze

ERIC R. BIXON FRANK A. GAGLIARDI AMSTA-AR-QAT-P FEBRUARY 12, 2003

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M234/XM235 Description
M234/XM235 Self Destruct Fuze (SDF) is a state of the art electro-mechanical fuze for DPICM bomblets with an independent self destruct feature
M234 for use on 105mm artillery & mortar projectiles XM235 for use on MLRS rockets XM236 for use on 155mm artillery
M234 SDF

Addresses Humanitarian Issues (UXO) Improves Maneuver Forces Mobility Dramatically Reduces the Hazardous Dud Rate
99.5% Reliability Demonstrated in ER-MLRS 99.8% Reliability Demonstrated in M915 105mm Projectile Without SDF

M80 Grenade with M234 SDF

With SDF

Fire 100 M915 Cartridges:

42 grenades per cartridge 4200 total M80 grenades 126 Fuzed Duds 8 Fuzed Duds

 THE BATTERY IS A LITHIUM RESERVE BATTERY THE BATTERY HOUSING CONTAINS A GLASS/STEEL AMPULE FILLED WITH A SULFURYL CHLORIDE-BASED ELECTROLYTE WHEN THE AMPULE BREAKS, THE SULFURYL CHLORIDE CONTACTS THE LITHIUM AND THE BATTERY IS ACTIVATED

CHEMISTRY OF THE BATTERY

Lithium Battery
Lithium Anode Electrolyte 1.5 M AlCl3 + SO2Cl2
Aluminum Chloride (Anhydrous) 11.83 Weight percent Sulfuryl Chloride 88.16 Weight Percent

Overall Chemical Reaction for Lithium reacting with Sulfuryl Chloride

Lithium is oxidized

2 Li 2Li + + 2e
And Sulfur is reduced

2 Li + SO2Cl2 SO2 + 2 LiCl

SO2Cl2 + 2e 2Cl + SO2

Other Chemical Reactions Occurring in the System

Other Chemical Reactions Occurring in the System

complex ion

2 AlCl 3 + Cl2 + 2 e 2 AlCl 4

SO2 Cl + + AlCl 4 SO2Cl + ( AlCl 4 )

SO2Cl2 SO2 (g ) 2SO2Cl2 2 SO2 Cl + +

+ Cl 2 (g) Cl2 +62e

BACKGROUND
An Accelerated Test Program has been started on the M234 battery to investigate potential failure mechanisms which may have an impact on the shelf life The objective of the program is to verify the 20 year shelf life requirement for the battery
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BACKGROUND (cont)
The tested samples were batteries designed and produced by ATK Power Sources Center in Horsham, PA L3-KDI in Cincinnati, OH, is currently under contract to develop a high-rate automated assembly line to produce an improved version of the ATK battery design

Summary of Experiments
Determine ampule breaking point via Progressive Stress Experiment Determine battery failure modes via Isothermal Experiments

Summary of Experiments (cont)

Determine ampule breaking point via Progressive Stress Experiment

Run 1: Progressive Stress Experiment from 70 F to 340 F to determine temperature range at which ampule fractures and battery activates

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Summary of Experiments (cont)

2. Determine battery failure modes via Isothermal Experiments

Isothermal experiments
Run 2: 275 F for 216.8 hours Run 3: 295 F for 47 hours Run 4: 300 F for 87.6 hours Run 5: 250 F for 21 days Run 6: 184 F (84.7 C) for 29 days and 7 hours Ambient Controls
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Summary of Experiments (cont)

2. Determine battery failure modes via Isothermal Experiments (cont)

Investigate Potential Failure Mechanisms
Ampule Leakage generation of ghost voltages in storage Electrolyte Degradation/Decomposition Corrosion due to reaction of sulfuryl chloride with the metal

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Part 1: Progressive Stress Experiment

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Part 1: Progressive Stress Experiment (cont)

BLUF: Run 1 Results Two batteries activated during accelerated aging due to expansion of the electrolyte in the ampules and fracture of the ampule at temperatures over +310 F
(Required battery temperature functioning range: -50F to +145F)

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Run 1 - Temperature as a Function of Time

400 TEMPERATURE IN FAHRENHEIT

300

200

100

0 0 50 100 Time in Hours

HOURS vs DEG F

150

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Run 1 - Channel 6 - Accelerated Aging

5.00

Tactivation 319.7 F
4.00 3.00 Volts 2.00 1.00 0.00 0 50 100 Time in Hours
HOURS vs CHANNEL 6

150

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Run 1 - Channel 8 - Accelerated Aging

5.00

Tactivation 310.2 F
4.00 3.00 Volts 2.00 1.00 0.00 0 50 100 Time in Hours
HOURS vs CHANNEL 8

150

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Part 2: Determine battery failure modes via Isothermal Experiments

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Part 2: Determine battery failure modes via Isothermal Experiments (cont)

Battery Performance Requirements of Interest
Battery must reach 3.6V within 60 seconds after activation at hot temperatures Battery must maintain 3.6V minimum for 10 minutes after activation at all temperatures

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Part 2: Determine battery failure modes via Isothermal Experiments (cont)

Battery Activation Data

DATA OBTAINED DURING ACCELERATED AGING CYCLE Sampling Rate = one reading every 189 seconds PERFORMANCE DATA AFTER AGING WHEN BATTERY IS ACTIVATED AND PERFORMANCE IS MEASURED Sampling Rate = one reading per second BOTH TYPES ARE VOLTAGE vs TIME
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Part 2: Determine battery failure modes via Isothermal Experiments (cont)

Battery Activation Data (cont)

Summary of Activation Procedures -Most Activations were at ambient -In Some Cases the batteries were conditioned at -55 F for 24 hours -Then they were withdrawn and activated within 60 seconds, but generally, the time to activate was about 30 seconds

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Part 2: Determine battery failure modes via Isothermal Experiments (cont)

Baseline Performance Data Obtained On Unconditioned Batteries

Peak Voltage Estimate Voltage Degradation Rate Over a ten minute interval Rise Time = time to reach 3.6 volts
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Sample 2 - Unconditioned Activation Curve

5.00

4.00

3.00 Volts 2.00

1.00

Peak Voltage = 4.1920 Volts @ t = 39 seconds

0 100 200 300 Time in Seconds
OBSERVED VOLTAGE DURING ACTIVATION

0.00 400 500 600

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Peak Voltage = 4.1920 Volts @ t = 39 seconds

4.50

4.25

Volts

? Y
4.00

3.75

3.50 0 100 200

? X

300

400

500

600

Time in Seconds

Voltage Degradation Rate = ? Y/ ? X

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Sample 2 - Unconditioned Activation Curve

5.00

4.00

3.00 Volts

2.00

Rise Time < 1 sec (t until 3.6 volts)

1.00

0.00 0.00

1.00

2.00

3.00

4.00

5.00

Time in Seconds
Observed Voltage PREDICTED

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Part 2: Determine battery failure modes via Isothermal Experiments (cont)

CHARACTERIZATION OF AMPULE LEAKS

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Part 2: Determine battery failure modes via Isothermal Experiments (cont)

SMALL LEAKS
Accelerated Aging
CHANNEL 7 -ACCELERATED AGING RUN 2
0.10
5.00

5 Second Performance
Channel 7 Run 2 - Activation Curve

0.08

4.00

VOLTAGE

Volts 2.00 1.00 0.00 0.00

0.06

3.00

0.04

0.02

0.00 0 50 100 150 200 250 TIME IN HOURS

HOURS vs CH07

1.00

2.00

3.00

4.00

5.00

Time in Seconds
Col 2 vs Col 3 x column vs y column

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Part 2: Determine battery failure modes via Isothermal Experiments (cont)

LEAKS THAT STOP AND START

Accelerated Aging
CHANNEL 8 -ACCELERATED AGING RUN 2 275 F
5.00
0.10

5 Second Performance
Channel 8 Run 2 - Activation Curve

4.00
0.08

VOLTAGE

Volts 2.00 1.00

0 5 30 40 50

0.06

3.00

0.04

0.02

0.00 TIME IN HOURS

VOLTAGE VS TIME

0.00 0.00

1.00

2.00

3.00

4.00

5.00

Time in Seconds
Col 2 vs Col 3 Col 12 vs Col 13

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Part 2: Determine battery failure modes via Isothermal Experiments (cont)

LEAKS THAT STOP

Accelerated Aging
CHANNEL12 - ACCELERATED AGING RUN 2 275 F
0.10

5 Second Performance
Channel 12 - Run 2 Activation Curve
5.00

4.00

0.08

3.00
VOLTAGE 0.06

Volts 2.00 1.00

0 1 2 3 TIME IN HOURS
HOURS vs CH12

0.04

0.02

0.00 200 225

0.00 0.00

1.00

2.00

3.00

4.00

5.00

Time in Seconds

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Col 2 vs Col 3 x column vs y column

Part 2: Determine battery failure modes via Isothermal Experiments (cont) AMPULES THAT FRACTURE OR ELSE ALL ELECTROLYTE LEAKED OUT
CHANNEL13 - ACCELERATED AGING RUN 2 275 F

2.0

1.5 VOLTAGE

No change in voltage When activated. Ampule Was fractured during Accelerated aging

1.0

0.5

0.0 0 50 100 150 200 250 TIME IN HOURS

HOURS vs CH13

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Part 2: Determine battery failure modes via Isothermal Experiments (cont)

SMALL LEAKS THAT INCREASE

Accelerated Aging
CHANNEL 10 - ACCELERATED AGING RUN 2 275 F
5.00
0.10

5 Second Performance
Channel 10 Run 2 - Activation Curve

4.00
0.08

3.00
VOLTAGE

Volts 2.00 1.00 0.00 0.00

0.06

0.04

0.02

0.00 0 50 100 150 200 250 TIME IN HOURS

OBSERVED VOLTAGE

1.00

2.00

3.00

4.00

5.00

Time in Seconds
Col 2 vs Col 3 x column vs y column

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Part 2: Determine battery failure modes via Isothermal Experiments (cont)

LARGE LEAKS WITHOUT AMPULE FRACTURE THAT AFFECT RISE TIME

Accelerated Aging
CHANNEL 6 -ACCELERATED AGING RUN 4 - 300 DEGREES F
5
5.00

40 Second Performance
Channel 6 - Run 4 - First 40 Seconds of Activation Curve

4.00

VOLTAGE

3
Volts

3.00

5 additional seconds to reach 3.6 Volts

2.00

1.00 5 Second Delay Time

0 0 20 40 60 80 100 TIME IN HOURS

HOURS vs ch06

0.00 0 10 20 Time in Seconds 30 40

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Col 3 vs Col 4

Part 2: Determine battery failure modes via Isothermal Experiments (cont)

LARGE LEAKS (OR AMPULE FRACTURE) CAUSING BATTERY FAILURE UNABLE TO REACH PEAK VOLTAGE
Accelerated Aging
CHANNEL 7 -ACCELERATED AGING RUN 4 300 DEGREES F
5

5 Second Performance
Channel 7 - RUN 4 - Activation Curve Fixture activated at 15 seconds Little or no change in Volts Ampule was already broken or all electrolyte leaked out
5.00
SPECIFICATION REQUIREMENT = 3.6 VOLTS

4.00

VOLTAGE

3.00 Volts

2.00

1.00

0 0 20 40 60 80 100 TIME IN HOURS

HOURS vs CH07

0.00 0 100 200 300 400 500 600 Time in Seconds

TIME vs VOLTS CH7 Col 4 vs Col 5

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Part 2: Determine battery failure modes via Isothermal Experiments (cont)

Summary of Types of Leaks

Small Leaks Large Leaks Leaks that start and seal up Leaks that get worse
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Part 2: Determine battery failure modes via Isothermal Experiments (cont)

STATISTICAL RESULTS

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RISE TIME IN SECONDS BY GROUP

Oneway Analysis of RISE TIME IN SECONDS By INDEX-RUN TYPE
15 RISE TIME IN SECONDS 12.5 10 7.5 5 2.5 0 84.4 for COLD250 Cold Phase RUN 2 CONTROLS INDEX-RUN TYPE RUN 3 RUN 4 RUN 5

Rise Time Longer Due To Delay Run 4 300 F

Oneway Anova Analysis of Variance

Source INDEX-RUN TYPE Error C. Total DF Sum of Squares 7 21 28 291.77722 13.33575 305.11297 Mean Square 41.6825 0.6350 F Ratio 65.6380 Prob > F <.0001

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PEAK VOLTAGES BY GROUP All Runs Over 250 F Resulted in Slight Decrease in Peak Voltage

Oneway Analysis of ALL - LEAKS By INDEX - LEAKS

4.2

4.15 ALL - LEAKS

4.1

4.05

4 84.4 for COLD - COND CONTROLS Cold Phase RUN 2 RUN 3 RUN 4 RUN 5

INDEX - LEAKS

Oneway Anova Analysis of Variance

Source INDEX - LEAKS Error C. Total DF Sum of Squares 7 21 28 0.08534050 0.00549695 0.09083745 Mean Square 0.012191 0.000262 F Ratio 46.5752 Prob > F <.0001

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DEGRADATION RATE IN VOLTS/SEC BY GROUP

DEGRADATION RATE IN VOLTS/SEC

Oneway Analysis of DEGRADATION RATE IN VOLTS/SEC By INDEX-RUN TYPE

0.0007 0.0006 0.0005 0.0004 0.0003 0.0002 0.0001 84.4 for COLD - COND Cold Phase CONTROLS RUN 2 INDEX-RUN TYPE RUN 3 RUN 4 RUN 5

High Degradation rates for these two

Oneway Anova Analysis of Variance

Source INDEX-RUN TYPE Error C. Total DF 7 20 27 Sum of Squares 5.0084e-8 2.95398e-7 3.45482e-7 Mean Square 7.1549e-9 1.477e-8 F Ratio 0.4844 Prob > F 0.8346

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Part 2: Determine battery failure modes via Isothermal Experiments (cont)

SUMMARY OF RESULTS
PRIMARY FAILURE MODE: Peak Voltage failure due to leaking or ampule fracture
Only way to force the batteries to go out of SPECIFICATION was to induce leaking of electrolyte in sufficient quantities so that batteries could not meet peak voltage

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CONCLUSIONS
Accelerated Aging produced a negligible effect on battery performance, including peak voltages, rise times and voltage degradation rates

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CONCLUSIONS

Leaking out of the electrolyte was the only technique that could induce failure of the battery to meet the peak voltage specification requirement.

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CONCLUSIONS
BATTERIES ARE EXTREMELY ROBUST ELECTROLYTE IS VERY GOOD BATTERY VOLTAGE DEGRADES VERY LITTLE DURING THE 10 MINUTE REQUIRED OPERATION TIME
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FUTURE WORK
DEVELOP MODEL WHICH PREDICTS LEAKAGE PROFILES AS A FUNCTION OF TEMPERATURE AND TIME CHARACTERIZE AMPULE FRACTURE DISTRIBUTION AS A FUNCTION OF ACCELERATING TEMPERATURE
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FUTURE WORK
PROVIDE SERVICE LIFE ESTIMATE EVALUATE NEW, IMPROVED DESIGN FOR AMPULE INVESTIGATE PEAK VOLTAGE DEGRADATION FOR BATTERIES THAT DID NOT LEAK
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FUTURE WORK
ALL FUTURE ACTIVATIONS SHALL BE DONE AT 50 F ANY DEGRADATION EFFECT ON THE RISE TIME WILL BE MORE DISCERNIBLE AT 50 F

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FUTURE WORK
DEVELOP NEW ACTIVATION FIXTURE WHICH CAN BE ACTIVATED INSIDE CHAMBER KEPT AT 50 F

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EXPERIMENTAL SETUP

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Acknowledgements
The authors wish to thank the following colleagues without whose support this work could not have been accomplished. The M234 SDF USG IPT at Picatinny Arsenal, NJ, including (but not limited to) the following: Bill Vogt Jim Murnane Joseph Donini Lawrence Raniere Sing Eng Leon Springer

The M234 SDF Program Staff at L3-KDI, Cincinnati, OH, including (but not limited to) the following: Bob Rankin Mike Steele

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